Example Inventory 3 Source Group 2 Ferrous and Non-Ferrous Metal Production

The baseline inventory of country X was conducted in 2006 using data collected for the 2004 reference year, according to the 2005 Toolkit methodology.

Using the following information sources, a list of relevant activity types and facility names was produced:

1. Listings of industrial activities in the Associations representing the sector,
2. Customs databases for imports of inputs for the foundry industry,
3. Industrial activities listed in trade guides for product offers,
4. Local authorities (Districts, Municipalities) and national government (Ministry for Environment).

Based on the questionnaire for Group 2 – Ferrous and Non-Ferrous Metal Production (Annex 3 of the Toolkit), an adapted questionnaire was developed and sent by e-mail or via fax in 2006, to the list of industries obtained. The heads of each company were requested to complete the necessary information and the activity data for reference year 2004.

Of the twelve categories of sources in this group, only four are relevant to the country in the 2004 baseline year, and are detailed below:

• 2c Iron and steel production and foundries,
• 2d Copper production,
• 2e Aluminum production,
• 2l Thermal wire reclamation.

In 2006 no information was available on activity levels and technologies for the metals smelting sector. To overcome this, the questionnaire was sent to all industries identified, a total of 11. All of them are engaged in secondary smelting of different materials with different qualities, as Country X has not developed primary production of metals from ores. Of all industries, a sample of 5 was selected to be visited in order to verify the correct interpretation of the information requested in the questionnaire and the degree of accuracy of the information submitted by the responsible of the company.

The facilities visited were those with activities considered as more sensitive in the estimates of PCDD/PCDF emissions, either by the level of activity or the production and control technologies used. The companies selected covered between 80 and 85% of total ferrous and non ferrous production, so this helped to improve the confidence of the emissions estimates in this sector.

Open burning of stolen cables from power and telephone lines is an informal activity which frequently takes place in the country. The allowed recovery technology is the peeling of wire for subsequent entry into smelting furnaces, without PVC or other plastic materials. The informal activity is performed in poor conditions. The stolen wire amount in 2004 was obtained from the electricity transmission companies and from the telephone companies.

2c Iron and Steel Production and Foundries

In this subcategory a total of five facilities were identified, among which two produce a total of 120,000 tones of liquid steel a year, and three were iron foundries with a production of 30,000 tons per year. They were ordered into four classes taking into account the technologies used.

Source category	Class		Production (t/a)	Annual release (g TEQ/a)					Sub-Total (g TEQ/a)
				Air	Water	Land	Product	Residue
Iron and steel plants	1	Dirty scrap, scrap preheating, limited controls	20,000	0.200				0.300	0.50
	2	Clean scrap/virgin iron, afterburner, fabric filter	-
	3	Clean scrap/virgin iron, BOF furnaces	-
	4	Blast furnaces with APC	100,000	0.001					0.00
Sub-Total			120,000	0.20	0	0	0	0.300	0.50
Foundries	1	Cold air cupola or rotary drum, no APCS	10,000	0.100					0.10
	2	Rotary drum - fabric filter	20,000	0.086				0.004	0.09
	3	Cold air cupola, fabric filter	-
	4	Hot air cupola or induction furnace, fabric filter	-
Sub-Total			30,000	0.186	0	0	0	00	0.19
Total		Iron and steel production plants and foundries	150,000	0.388	0	0	0	0.304	0.69

2d Copper Production

A total of three companies were identified as active in secondary smelting of copper, with a total production of 68,000 tons per year. Among these, 60,000 tons are produced in modern, well-operated plants, with a rapid quench system, bag filters and filter activated carbon. In this way, emissions are captured in the gas treatment system, while waste generated through the process is better controlled. The remaining 8,000 tons are produced in two basic technology plants without controls.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Sec. Cu - Basic technology	8,000	6.400				5.040	11.44
2	Sec. Cu - Well controlled	-
3	Sec. Cu - Optimized for PCDD/PCDF control	60,000	0.300				18.000	18.30
4	Smelting and casting of Cu/Cu alloys	-
5	Prim. Cu, well-controlled, with some secondary feed materials	-
6	Pure prim. Cu smelters with no secondary feed	-
Total	Copper production	68,000	6.700	0	0	0	23.0	29.8

2e Aluminum Production

This sector involved a total of three plants for secondary aluminum production using scrap of varying quality. The emissions for the two classes are presented in the following table. It is worth mentioning that in the present case these values are rather low, without significant variations between the different classes.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Processing scrap Al, minimal treatment of inputs, simple dust removal	5,000	0.750				1.000	1.75
2	Scrap treatment, well controlled, good APCS	-
3	Scrap treatment, well-controlled, fabric filter, lime injection	15,000	0.075				1.500	1.58
4	Optimized proces for PCDD/PPCDF abatement	-
5	Shavings/turnings drying (simple plants)	-
6	Thermal de-oiling, rotary furnaces, afterburners, fabric filters	-
7	Pure primary Al plants	-
Total	Aluminum production	20,000	0.825	0	0	0	2.5	3.3

2l Thermal Wire Reclamation and e-waste recycling

To estimate emissions from wire burning, it was assumed that all stolen cables were burned in the open, so the country's copper smelters only receive bare wires. This will lead to an overestimation of the emissions which is however found acceptable due to lack of other information. It is estimated that a total of 600 tones of cables were burned in the open in 2004. This is based on the length of stolen wire and weight per kilometer (kg /km), as provided by electricity transmission companies and phone companies. It was also assumed that the activities of electronic scrap recovery take place nationwide.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Open burning of cable	600	3.000					3.00
2	Basic furnace with after burner, wet scrubber	-
3	Burning electric motors, brake shoes, etc., afterburner	-
Total	Thermal wire reclamation	600	3.000	0	0	0	0	3.0

As part of the National Implementation Plan, the Country X has implemented a set of measures to reduce the generation and release of unintentional POPs. The baseline inventory was updated in 2013to assess whether the implementation of such measures was successful. The Toolkit as revised in 2013 was used as a basis for updating release estimates. The update served to assess both the changes in volumes and types of activity taking place in the country, as well as the effectiveness of measures implemented to reduce levels of emissions.

The measures implemented to reduce the PCDD/PCDF emissions from other source categories, in particular waste management, and the rising value of metals on the market, has led to an increase in waste recycling and increasing rates of metal scrap recovery, mainly ferrous.

In addition, during the baseline survey performed in 2006 to produce the baseline inventory, several gaps in information were detected. Therefore the Government decided to require registration of smelting activities through the Ministry of Environment. Through this government decision, companies are obliged to update their information every four years. Due to this initiative, necessary information was readily available for processing, and the time needed to update the inventory was significantly reduced. This also allowed to identify the leading smelting activity in Country X, which had not been detected in the first inventory.

2c Iron and Steel Production and Foundries

In 2010, the same five industries remain, with an increase of 33% in production, which are still insignificant compared to the total releases form Group 2.

Source category	Class		Production (t/a)	Annual release (g TEQ/a)					Sub-Total (g TEQ/a)
				Air	Water	Land	Product	Residue
Iron and steel plants	1	Dirty scrap, scrap preheating, limited controls	25,000	0.250				0.375	0.625
	2	Clean scrap/virgin iron, afterburner, fabric filter	-
	3	Clean scrap/virgin iron, BOF furnaces	-
	4	Blast furnaces with APC	130,000	0.001					0.001
Sub-Total			155,000	0.251	0	0	0	0.375	0.626
Foundries	1	Cold air cupola or rotary drum, no APCS	5,000	0.050					0.050
	2	Rotary drum - fabric filter	40,000	0.172				0.008	0.180
	3	Cold air cupola, fabric filter	-
	4	Hot air cupola or induction furnace, fabric filter	-
Sub-Total			45,000	0.222	0	0	0	0.0	0.230
Total		Iron and steel production plants and foundries	200,000	0.47	0.00	0.00	0.00	0.38	0.86

For the year 2012, a new steel facility will be installed which will process 160 ton/day. This will be a Class 3 electric arc furnace plant equipped with air pollution control systems designed for lower PCDD/PCDF emissions. The government is also interested in projections of future releases to know how these will impact in the overall PCDD/PCDF emissions. The Toolkit 2013 methodology was thus used to forecast the new emissions showing an increase of +0.058 g TEQ/a in waste and in air emissions. This represents a net increase of 13.5% in this sub-category when compared to the 2010 scenario.

2d Copper Production

Further to the baseline survey conducted in Country X, according to which copper production accounted for 83% of the total PCDD/PCDF emissions from source group 2, the authorities implemented a plan to improve emission control in the copper foundry sector focusing on two aspects: adequate waste disposal to mitigate the impact on the environment, and upgrading of the two plants producing 8,000 t/a with basic technology. As a result, 6,000 tons are now produced with good air pollution control, and were moved from Class 1 to Class 2.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Sec. Cu - Basic technology	2,000	1.600				1.260	2.860
2	Sec. Cu - Well controlled	6,000	0.300				3.780	4.080
3	Sec. Cu - Optimized for PCDD/PCDF control	60,000	0.300				18.000	18.300
4	Smelting and casting of Cu/Cu alloys	-
5	Prim. Cu, well-controlled, with some secondary feed materials	-
6	Pure prim. Cu smelters with no secondary feed	-
Total	Copper production	68,000	2.200	0	0	0	23.0	25.2

2e Aluminum Production

In 2010, for the plants operated in Class 3 two aspects can be highlighted:

• the secondary aluminum production increased by 33% and
• 50% of solid residues were recycled internally, so waste emissions should be divided by two.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Processing scrap Al, minimal treatment of inputs, simple dust removal	5,000	0.750				1.000	1.750
2	Scrap treatment, well controlled, good APCS	-
3	Scrap treatment, well-controlled, fabric filter, lime injection	20,000	0.100				8.000/2 = 4.000	4.100
4	Optimized proces for PCDD/PPCDF abatement	-
5	Shavings/turnings drying (simple plants)	-
6	Thermal de-oiling, rotary furnaces, afterburners, fabric filters	-
7	Pure primary Al plants	-
Total	Aluminum production	25,000	0.850	0	0	0	5.0	5.9

2f Lead Production

The information available for the 2010 reference year shows that lead battery components free of PVC are used for smelting in rotary kiln with fabric filter, corresponding to Class 2.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Sec. lead from scrap, PVC battery separators	-
2	Sec. from PVC/Cl2 free scrap, some APCS	10,000	0.080				0.050	0.130
3	Sec. Lead, PVC/Cl2 free scrap in modern furnaces, with scrubber	-
4	Pure primary lead production	-
Total	Lead Production	10,000	0.080	0	0	0	0.05	0.13

2l Thermal Wire Reclamation and e-waste recycling

In 2010, it is estimated that 400 tons of wire have been burned in the open. This is less than for the baseline year (2004), due to changes in above-ground wires to underground wires, which decreases the possibility of theft.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Open burning of cable	400	4.800					4.80
2	Basic furnace with after burner, wet scrubber	-
3	Burning electric motors, brake shoes, etc., afterburner	-
Total	Thermal wire reclamation	400	4.800	0	0	0	0	4.8

In order to be able to compare the 2010 updated release estimates with the baseline inventory for 2004 to mark the progress in reducing PCDD/PCDF, the following aspects must be taken into account:

1. Classification of sources and emissions factors may vary due to revisions of the Toolkit.
2. Further activities were identified in 2010, for which data were not available in 2006.

The emission for 2004 need to be recalculated using the 2013 Toolkit to enable comparison. The following table summarizes PCDD/PCDF emissions for a quick comparison between the 2004 and 2010 inventories.

Cat.	Class	Source categories	2004 recalculated						2010
			Production (t/a)	Annual release (g TEQ/a)				Production (t/a)	Annual release (g TEQ/a)
				Air	Residue	Total			Air	Residue	Total
c		Iron and steel production plants and foundries	150,000	0.387	0.304	0.69		200,000	0.473	0.383	0.86
		Iron and steel plants	120,000	0.201	0.3	0.50		155,000	0.251	0.375	0.63
	1	Dirty scrap, scrap preheating, limited controls	20,000	0.2	0.3	0.50		25,000	0.25	0.375	0.63
	4	Blast furnaces with APCS	100,000	0.001	-	0.001		130,000	0.0013	-	0.001
		Foundries	30,000	0.186	0.004	0.19		45,000	0.222	0.008	0.23
	1	Cold air cupola or hot air cupola or rotary drum, no APCS	10,000	0.1	-	0.10		5,000	0.05		0.05
	2	Rotary drum - fabric filter or wet scribber	20,000	0.086	0.004	0.09		40,000	0.172	0.008	0.18
d		Copper production	68,000	6.7	23.04	29.7		68,000	2.2	23.04	25.2
	1	Sec. Cu - Basic technology	8,000	6.4	5.04	11.4		2,000	1.6	1.26	2.9
	2	Sec. Cu - Well controlled	-	-	-	-		6,000	0.3	3.78	4.1
	3	Sec. Cu - Optimized for PCDD/PCDF control	60,000	0.3	18	18.3		60,000	0.3	18	18.3
e		Aluminum production	20,000	0.825	7	7.8		25,000	0.85	5	5.9
	1	Processing scrap Al, minimal treatment of inputs, simple dust removal	5,000	0.75	1	1.75		5,000	0.75	1	1.75
	3	Scrap treatment, well-controlled, fabric filter, lime injection	15,000	0.075	6	6.08		20,000	0.1	4	4.10
f		Lead production	10,000	0.08	0.05	0.13		10,000	0.08	0.05	0.13
	2	Sec. from PVC/Cl2 free scrap, some APCS	10,000	0.08	0.05	0.13		10,000	0.08	0.05	0.13
l		Thermal wire reclamation and e-waste recycling	600	7.2	0	7.20		400	4.8	0	4.80
	1	Open burning of cable	600	7.2		7.20		400	4.8		4.80
Ferrous and Non-Ferrous Metal Production			647,200	15.2	30.4	45.6		806,800	8.4	28.5	36.9

It is observed that although a 25% increase has been registered in the production of metals from 2004 to 2010, total emissions from this source group have decreased by 19% overall. The total air emissions from metal production have been mostly impacted, with a total decrease of 45%.

The following sections show the revised calculations of the baseline inventory for each category.

2c Iron and Steel Production and Foundries

For this category is not necessary to recalculate the baseline releases, as the difference between the estimated emissions for both inventories is only due to increased production levels. In this category a 33% increase in production is registered. As this increase is based on adoption of improved technologies, there is not a consequent appreciable increase in emissions.

2d Copper Production

For this category is not necessary to recalculate the baseline releases. The decrease of 4.5 g TEQ/a in air emissions from 2004 to 2010 (15%) is also due improved technology in 2010.

2e Aluminum Production

For this category, it is necessary to recalculate the baseline releases due to the revision of the waste emission factor (for class 3, this changed from 100 to 400 µg TEQ /t).

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Processing scrap Al, minimal treatment of inputs, simple dust removal	5,000	0.750				1.000	1.75
2	Scrap treatment, well controlled, good APCS	-
3	Scrap treatment, well-controlled, fabric filter, lime injection	15,000	0.075				6.000	6.075
4	Optimized proces for PCDD/PPCDF abatement	-
5	Shavings/turnings drying (simple plants)	-
6	Thermal de-oiling, rotary furnaces, afterburners, fabric filters	-
7	Pure primary Al plants	-
Total	Aluminum production	20,000	0.825	0	0	0	7.0	7.8

Thus, in this category, a 33% increase in production produced an increase of 2 g TEQ/a in waste, which represents an increase of 26% compared to 2004 emissions in the secondary aluminum production.

2f Lead Production

For the year 2004, lead from battery components was melted in country X. However, this activity was not considered in the baseline inventory as it was not detected due to limitations in the survey. This new information should be included in the revised baseline inventory.

From the information available, it is estimated that in 2004, the activity took place at the same facility as in 2010, and with the same level of production, resulting in the same emissions than those estimated in 2010.

2l Thermal Wire Reclamation and e-waste recycling

Despite lower amounts of wire burnt in the open in 2010, by comparing to 2004 and 2010 release levels, PCDD/PCDF emissions are shown to increase. This is because the air emission factor for open burning of cable has been revised and is significantly higher in the Toolkit 2013 than in the 2005 edition. Therefore the baseline releases need to be recalculated using the revised emission factor.

Class		Production (t/a)	Annual release (g TEQ/a)					Sub- Total (g TEQ/a)
			Air	Water	Land	Product	Residue
1	Open burning of cable	600	7.200					7.20
2	Basic furnace with after burner, wet scrubber	-
3	Burning electric motors, brake shoes, etc., afterburner	-
Total	Thermal wire reclamation	600	7.200	0	0	0	0	7.0

Thus, the decrease in releases from this source category is directly proportional to the decrease in the amount of burned wires, i.e. by 33%.